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August 2014

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Collapse IMTS Product PreviewIMTS Product Preview
Live Demonstration of Automated Machining Cell
New CNC Control for Knee Mills
Machine Tool Component Products
TC64-RG Roughness Gauge
New Laser Line Sensors Enable Reverse Engineering
Latest Version of Machining Simulation Software
Dynamic Motion Technology
Delcam to Preview FeatureCAM and PowerMILL 2015
Advanced CNC Automation
Robot Machines and Grinds Castings
Software Designed to Shorten Cycle Time
GibbsCAM Universal Kinematic Machine Software
Enterprise Resource Planning Document Control
Turbine Blade Wire EDM Ring Machine
Dynamic Precision and Dynamic Efficiency Controls
Machine Protection Products
New Laser Scanner for ROMER Absolute Arms
HPB to Feature Motion Control Products
New High-Speed Spindles
Versatile Mobile Surface Measurement System
Thread Inspection Systems
Introducing MunchMan II Conveyor
ECO Compact 20 Pallet Automation System
Linear Rotary Motor with Gearbox
New Video Measuring Microscope
High Accuracy Visual Tool Setter for Small Tools
Reduced Maintenance Chip Conveyor
New Solenoid Valve Connectors
New Copper-Impregnated Ultra-Fine Grain EDM Graphite
Fully Automated Measurement Technology
Multi-Touch Industrial Fieldbus Panel PCs for the Smart Factory
CNC Control Advances
Industry Expert to Speak at IMTS Olympus Booth
Flexible PartMaker Version 2015 to be Previewed
Fiber Lasers and Precision Laser Technology
Quality Vision International to Offer Educational Series
High Performance Blade Measurement and Analysis Tools
Siemens Showcases Family of CNCs
Rigid Linear Motor Driven Technology
What You See is What You Cut - WYSIWYC
Sensing and Signaling Products for Protection Detection and Safety
Third Wave Systems to Release Production Module 7.0
New CMM Automation Software
Oil Mist Separation Line
Model 8 Parts Washer
Robot Automation Technologies
Modular Fixturing Technology
Sump Sharks Clean Dirty Sumps
C-510MNC Miter Bandsaw
New Parts Cleaning and Collection Unit
Large Format High-Speed Milling Machine
Modular Manufacturing Systems and Gear Hobbing
Side-Load Robotic Welding Cell
Gear Honing Technology
Twin Turret Grinder to be Unveiled
Modular Design Waterjet Cutting
Precision Laser Marking Technology with Vision System
GMTA Machine Lineup
Greenerd to Showcase Hydraulic Press
Robotic Blast System with Tool Changer
Precision Grinding Machines
Camera Based 3D Measuring System for Robot Grinding Cells
Latest 5-Axis Waterjet Cutting Technology
New Gear Grinders and Portable Gear Inspection System
Compact PumpSkimmer Features Magnetic Frame
Vertical Lathes Equipped for I.D.O.D. Turning
New Gear Shaping Machine
Robotic Bin Picking Automation
Furnaces on Display
Introduction of New Tool and Process Monitoring System
New Larger Part EDM and Additive Machine
Bonded Abrasives for Precision Grinding
Micro Waterjet Machining
Replace Three Bandsaws with One Circular Saw
Chip Processing Systems and Conveying Technology
Non-foaming Metalworking Fluids
Hard Gear Finishing and Polish Grinding
Five-axis CNC Tool Grinder
New GSU Series CNC Universal Grinder
New Band Saw Blade Simulator Program
Tool Cutter Grinder and Gear Grinders
Adjustable Rest for BuildPro Modular Welding Tables
Heavy-Duty Bore Gages for Large Parts
New Filter Technology and Applications
Mobility in Laser Marking
New Minimum Quantity Lubrication System
Nineteen Grinding Machines
FZ17 Series Coalescer for Oil Skimming
Swiss Lathes Simple Lathes and Micro Drilling Machines
ACER to Showcase Variety of Metalcutting Machines
Combined Automatic Sawing and End Machining
Master 80HF-12 Bar Feeder
Box Ways and Linear Motion Guideways VMCs
Lathe Team with a Production Efficiency Demonstration
High-Speed and Multi-Function Machine Tools
Compact and Short Bar Loaders
APEC G Series 5-Axis High-Speed Gantry Machining Center
Large Horizontal Boring Milling Machines and Machining Centers
New Mill-Turn Multitasking Machines
New Vertical and Horizontal Machining Centers
New Stallion Series Turning Center
CNC Innovations for Improved Machining Performance
Multilevel FMS System 110 Scale Model
Heavy-Duty Machine Tools
Boring Mill with Robotic Tool Changer and Cylindrical Grinder
Horizontal Vertical and Turning Centers
Multi-operation Modular Machining
New Multitasking Machine Tools
Overcoming Labor Shortages Through Technology
5-Axis Machining and Automation
High-Speed 5-Axis Universal Machining Center
VTL Features Large Cast Iron Bed
Seven New CNC Swiss-Type Turning Center Models
Precision Turning Milling Grinding Machines
Reality TV Meets CNC at IMTS 2014
Reality TV Meets CNC at IMTS
Reality TV Meets CNC
Reality TV Meets CNC
Big Bore Turning Centers for Oil Field
Metalcutting and Automation Technology
New Turn-Mill Center with Motorized Milling Spindle
Big Bore Chucker Heavy-Duty Slant Bed Lathe
New 5-Axis VMC for Complex Components
Productivity Enhancing Barfeeders and Data Transfer System
New Machining Technologies and Automation Systems
Automation Solutions and Multi-pallet Systems
Multitasking and Productivity Combinations
Expansive Range of Machine Tools and Automation
Pallet Changers Adapt to Any Size Machining Center
Challenger Series HBM110XT Horizontal Boring Mill
Heavy-Duty HMC Designed for Aerospace and Power Generation
New High-Pressure Coolant Systems
New Twin-Spindle CNC Chucker and Gang Tool Lathe
Ball Valve Grinder
MA-12500H HMC on Display
New Swiss Laser Machine
New Heavy-Duty VMCs
VMC850E VMC for Job Shops
New T-type Horizontal Boring Machine
Portable Second-Op Machining Center
Productive Mid-Range Horizontal Machining Center
New Large Multitasking Turning Centers
Planer-Type Horizontal Machine
Toyoda to Debut Five New Machines
New Automatic Lathe for Productivity
Filterless Mist Collectors
Vertical and Swiss-type Turning Centers
Yamazen to Showcase Variety of Machine Tools
New FMC Systems for Lights-out Automation
AME to Feature Fixturing Products
New Broaching Tools and Angle Heads
BIG Kaiser Expands Line-Up
UltraGrip Precision Milling Chuck
New Coated Carbide Inserts and Customer Applications
Modular Industrial Benchtop Vending
New Battery Operated Lifter
High Performance Cutting Tools for Demanding Applications
INO System Spline Gages
Modular Quick-Change Tooling System
Clamps Fixturing Accessories Machine Tool and Material Handling Components
Multidec Lube Coolant Clamp
New Tool Holder Technology
Two Quick Changeover Workholding Systems
Multi-Flute Series Cutting Tools
Heule Tool Releases BSF Tool
Indexable Drill Head
Multi-Axis Low Profile Vise
Digital Tool Selector Expanding Capabilities
New Process Monitoring Device and Cutting Tools
Eight New Vises
Machine Tool Vise Jaws for Unbreakable Grip
Workspace and Storage Solutions
Lovejoy to Feature Cutters and Inserts
Magnetic Products for Industrial Applications
PVD TiAIN Coated Turning Inserts
Latest Rotating Carbide Tools
Made-to-order and Special Taps
New ER Toolholding Line
CoolanTool App Monitors Metalworking Fluids
Self-Locking Collet System Toolholders and More
Advanced Clamping and Gripping Technologies
New Clamping System for Face Grooving Shanks with Coolant Through Top and Bottom
New Tools Developed Around Modern Materials
New Rotary Broach Tools
BIG BORE BB-FZA2G Chuck
Machine-Ready Blanks
EZ-Lift Quality Certified Magnets
Compact MST Angle Heads
Sabre Wet Blasting System
Vardex Mega Line for Extra Large Pitches
Storage and Retrieval Systems
New Cutting Tool Technologies
New Dimensions for Measurement and Organization of Cutting Tools

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Robot Machines and Grinds Castings

Force Robots has introduced a new robotic system, called the Touch Robot, that is designed to perform precision grinding and machining to polish, deburr and deflash cast and forged parts. According to the company, metal finishing with hand tools is a dirty and difficult job that carries known repetitive stress injury risk. It is also a process that has proven extremely difficult to automate. Force Robots' system combines the precision of a machine with the finesse of the human hand. It can "feel" existing part contours, match it to a CAD reference and autonomously work to remove material to specification.

The Touch Robot is a compact, self-contained system requiring 120 VAC and shop air to operate. It consists of a 4-axis material removal arm and a 2-axis part positioner mounted to a 1.2 m x .8 m portable work table. Dividing the system's 6 degrees of freedom between the two coordinated mechanisms preserves the deft touch of the tool arm while permitting manipulation of heavy castings up to 0.4 m long. It has a simple and rugged construction designed for a finishing department environment. No fragile force or optical sensing is required to perform its work: all needed feedback is derived from the motor encoders. Its inherent safety features allow it to be deployed alongside manual metal finishing cells. Joint limits restrict its .5 m reach largely to the work table on which it is mounted. Low motor supply voltage (24Vdc) keeps joint speeds (max 300 deg/sec) below where the arm would develop dangerous levels of energy. With modest force capacity and low-friction, back-drivable joints, it is easily overpowered by a human. According to Steven Somes, the company founder, it changes the paradigm for a robotic work cell. "Most robots have to work independently and in isolation, surrounded by complex feeding and sensing systems. Our systems are simple; they can be used like a labor-saving appliance. Operators can task it with the heaviest, most difficult material removal work, while they focus on fine finishing and inspection."

"The Touch Robot performing delicate airfoil machining and turbine blade finishing presents a particular challenge because the parts require perfect smoothness on the micro level, while tolerating the macro-level dimensional variations of the casting process. That, plus the lack of easily referenced datum surfaces for locating, rules out machining to fixed coordinates. The Touch Robot begins operation by locating the workpiece with contact measurements, using the material removal tool as the probe. Machining and grinding passes are then performed with a well controlled, optimal contact force. With part geometry determining the tool path, the control software can identify the location and amount of excess material by comparing the tool trajectory to a CAD model reference. Automatically generated tool trajectories focus effort on the needed areas until the measured surface contour matches the CAD specification. This closed-loop mode of operation means the system delivers robust results despite numerous process variations, including part fixturing, the amount of material needing to be removed and the changing size and efficiency of the material removal tool. Despite initial geometry variation and uncertainty of up to several millimeters, the accuracy of the material removal is within a few tenths of a millimeter of the desired. This is because of the common datum reference between measurement and material removal. The absolute location of the workpiece is not important, only that the robot can discover it in the context of its material removal tool. Accuracy depends on the low error of differential kinematics," said a company spokesperson.

While part geometry varies widely, the types of casting artifacts requiring finishing are relatively few, e.g. parting lines, pin blips and core exit flash. According to the company, the programming software uses a parametric approach that allows predetermined strategies for these feature types to be invoked on a wide array of parts. Part programs are generated by filling in blanks on sequentially arranged function blocks within a web browser interface. Material removal tool poses and transition waypoints are identified by manually guiding the robot and part to the desired positions. Areas requiring finishing are designated by annotations on the part's CAD model within the provided software. Tool trajectories, contact forces and success metrics are dynamically generated at run time by the strategy using the user-provided parameters, geometry extracted from the CAD model and self-acquired part measurements.

The key to the system's success at working by force is its duplication of the dynamics of the human arm: low-friction joints, smooth actuation and low-inertia links. Each joint is driven by an anchor-shaped linkage with cables that attach at the tips and wrap across its arc-shaped perimeter. A brushless motor drives a capstan that winds the cables, imparting a magnifying torque to the linkage. The drive has no backlash and is torsionally stiff. Without rubbing or sliding components, it requires no lubrication, is long-lived and low in friction. The robot arm uses serially-connected cable drives for the first 3 joints and a compact harmonic drive actuator for the 4th tool joint. The part positioner uses a cable drive for its pitch axis and a direct-drive rotary stage for the yaw.

For more information contact:

Force Robots LLC

1768 E. 25th St.

Cleveland, OH 44114-4420

216-881-8360

www.forcerobots.com

IMTS 2014 Booth E-4746

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